30 TONNE HYDRAULIC PRESS - … · Thank you for purchasing this CLARKE 30 Tonne Hydraulic Press. ... Wear Safety Shoes Wear safety glasses ... F 1 x Pump Handle O 2 x Foot Pedal Connecting

30 TONNE HYDRAULIC PRESSMODEL NO: CSA30FP

PART NO: 7615200

OPERATION & MAINTENANCEINSTRUCTIONS

GC0516WARNING: Read these instructions before using the machine

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INTRODUCTION

Thank you for purchasing this CLARKE 30 Tonne Hydraulic Press.

Before attempting to operate the machine, it is essential that you read this manual thoroughly and carefully follow all instructions given. In doing so you will ensure the safety of yourself and that of others around you, and you can also look forward to the press giving you long and satisfactory service.

GUARANTEE

This CLARKE product is guaranteed against faulty manufacture for a period of 12 months from the date of purchase. Please keep your receipt as proof of purchase.

This guarantee is invalid if the product is found to have been abused or tampered with in any way, or not used for the purpose for which it was intended.

Faulty goods should be returned to their place of purchase, no product can be returned to us without prior permission.

This guarantee does not effect your statutory rights.

SAFETY SYMBOLS

The above safety symbols appear on the product.

Hazard;-shattered workpiece

Hazard:- crushed hands

Wear Safety Shoes Wear safety glasses

Read instruction manual before use

2arts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

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SAFETY PRECAUTIONS

• Due to the weight of the press, lifting equipment and the help of an assistant will be required during installation. Secure the press to a firm level floor using suitable anchor bolts (not supplied).

• Before starting work, check for signs of cracked welds, loose or missing bolts, damaged screen, or any other structural damage. Do not operate if any of these conditions exist. Have repairs made only by authorised service centre.

• Before work, always ensure that hydraulic hoses and couplings are completely sound.

• Never tamper with the press components or modify them. The safety valve is calibrated and sealed at the factory; do not attempt to change the setting.

• Use only the recommended hydraulic oil.

• The components of this press are designed to withstand the rated load. Do not substitute any other components or exceed the rated load of the press.

• Before applying pressure, ensure the workpiece is firmly secure and stable.

• Always clean up spills of hydraulic oil immediately as this can be dangerous in a workshop environment.

• Do not allow any person who is unfamiliar with hydraulic presses, to use the press unless they are under direct supervision.

• Keep children and unauthorised personnel away from the work area.

• Always position the safety screen directly front of the workpiece.

• Always apply the load under the centre of the ram. Offset loads can damage the ram and may cause the work piece to be ejected.

• Always ensure the work piece is properly supported by the press bed.

• When using accessories such as pressing plates, be certain they are centered below the ram and are in full contact with the bed.

• Parts being pressed may shatter or be ejected from the press. Always use adequate guards, and wear eye protection and protective clothing when using this press.

• Keep hands and fingers away from parts that may pinch or shift.

• Never use extension tubes to increase the length of the pump handle. Excessive effort can cause damage and/or accidents.

• Wear approved impact safety goggles and heavy duty work gloves.

• Failure to heed these warnings may result in damage to the equipment, or serious personal injury.


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UNPACKING & INVENTORY

Ensure the press and its components suffered no damage during transit and that all components are present. Should any loss or damage become apparent, please contact your CLARKE dealer immediately. The following items should be present in their packages.

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A 1 x Frame with ram / carrier assembly & hose

J 1 x Pressing Bed

B 2 x Base Supports K 4 x Bed Support Pins

C 4 x Stay Bars L 8 x Retaining Spring Clips

D 1 x Pump with hose attached M 2 x Bed Blocks (V-blocks)

E 1 x Pump Protective Cover N 1 x Protective Screen Assembly

F 1 x Pump Handle O 2 x Foot Pedal Connecting Bars

G 1 x Foot Pedal 1 x Fixing Kit (bolts,nuts, washers)

H 1 x Pressure Gauge


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ASSEMBLY

TOOLS REQUIRED• Wrench/socket set

• PTFE tape

• Hex key set

ASSEMBLY PROCEDUREIMPORTANT: The press must be firmly secured to a firm and level floor using expansion bolts (not supplied). Holes are provided in the feet for this purpose.

IMPORTANT: Do not locate your press where it will be open to the elements, as severe weather conditions will damage the hydraulic parts.

1. With the help of an assistant, attach the base supports to the frame using the nuts, bolts and washers.

2. Add the stay bars to each side and bolt into place.

3. Using suitable lifting equipment if required, lift the frame assembly upright and manoeuvre it to its intended location in the workshop.

4. Bolt the hydraulic pump into position on the side of the frame using the fixing bolts and washers.

WARNING: DUE TO THE WEIGHT OF THE PRESS, LIFTING EQUIPMENT OR THE HELP OF AN ASSISTANT WILL BE REQUIRED DURING INSTALLATION.


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5. Fit the pressure gauge through the frame and secure loosely with the large nut supplied Remove any protective bung from the gauge before fitting.

We recommend sealing all threads with PTFE tape where hydraulic oil is to be contained. Take care not to let any oil escape while connecting the hoses.

6. Screw the block connector and the connecting piece to the pressure gauge inlet.

7. Bolt the block connector to the back of the frame and connect the pump hose to the block connector as shown.

8. Connect the ram hose to the block connector.

9. Bolt the foot pedal to the frame using the long bolt, spacer tube, nut and washers.

10. Bolt the connecting bars to the operating arm of the pump. Bolt them together as a pair fitting the short spacers in both positions as shown.

11. Bolt the other end to the foot pedal.

12. Insert the bed support pins into the holes in the frame side supports at a height of your choosing. Secure them in position using the spring clips.


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13. Fit the protective cover over the pump assembly using the screws supplied.

14. Lift the pressing bed into position on the pins.

IMPORTANT: Due to the weight of the bed, we recommend that you get assistance from another person.

15. Bolt the protective screen brackets to the pressing bedplate.

16. Fit the protective screen to the pressing bed and ensure it can be set in one of the available positions using the latches on each side.


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PREPARATION FOR USE

PURGING THE HYDRAULIC SYSTEM1. Insert the pump handle into the

actuating lever.

2. Open the release valve by turning anti-clockwise.

3. Pump several full strokes to eliminate any air bubbles from the system. Use either the handle or the foot pedal.

4. Close the release valve by turning clockwise.

5. Top up the hydraulic oil to the lower level of the filler plug with CLARKE hydraulic oil, Part No. 3050830.

POSITIONING THE PRESSING BEDIMPORTANT: Due to the weight of the press bed, we recommend that you get assistance from another person when adjusting the bed height.

1. Position the pressing bed so that it will be as close as possible to the ram when the workpiece is mounted on it.

2. Raise one side of the bed and insert a bed supporting pin into the next locating hole.

3. Repeat at the other end to level the bed.

4. Repeat until the bed is at the required height, with the bed supporting pins are secured using the spring clips.

CAUTION: THE BED HEIGHT SHOULD ONLY BE RAISED OR LOWERED ONE HOLE AT A TIME, WORKING ALTERNATELY FROM ONE SIDE AND THEN THE OTHER, FAILURE TO WORK IN THIS WAY MAY CAUSE THE BED TO FALL AND CAUSE INJURY TO THE OPERATOR.


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POSITIONING THE RAM1. Slide the carriage along the cross-

beam.

2. Lock it in position with the four sprung locking bolts.

IMPORTANT: Always position the ram directly above the workpiece.

POSITIONING THE PRESSING BLOCKSThe bed blocks can be placed on the bed with either the flat face or the V-supports facing upwards.

They are prevented from slipping out of position by the retaining pins which drop down within the confines of the bed side members.

Check all parts are secure and correctly aligned before using the press.


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OPERATION

1. Place the workpiece on the bed. It must be completely stable and supported by packing or shims where required. Pressing plates (bed blocks) are supplied, which locate on the bed. Place the workpiece on these to give it stability.

NOTE: Any packing pieces or shims used MUST be capable of withstanding the pressure that will be brought to bear, and MUST be of sufficient size with sufficient surface area, so as to avoid the possibility of slipping or springing out. Mating surfaces MUST be horizontal so that the force being exerted will NOT be at an angle.

2. Close the release valve by turning clockwise until tightly closed.

3. Select either SLOW SPEED or FAST SPEED using the knob on the side of the pump cover.

NOTE: Fast speed allows faster movement but greater effort will be required.

4. Pump the handle or foot pedal to bring the ram very lightly into contact with the workpiece.

5. Manoeuvre the workpiece or loosen the bolts and slide the ram to one side so that the desired point of contact is directly beneath the centre of the ram.

6. When satisfied that the workpiece is correctly aligned and is completely stable in that position, raise the protective screen into position before starting any pressing.

7. Slowly pump the handle or foot pedal so that the ram begins to exert pressure on the workpiece.

CAUTION: DO NOT POINT LOAD SUCH ACCESSORIES AS THEY ARE NOT DESIGNED TO TAKE THE FULL FORCE OF THE RAM IN ONE SPOT. ENSURE THEY ARE ADEQUATELY SUPPORTED.


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8. Continue to pump the handle and constantly monitor the process, ensuring the ram and work remain completely in line and there is no risk of slipping.

9. Observe the reading on the pressure gauge and take care not to exceed the rated working pressure of the press.

NOTE: The scale from 30 metric tonnes upward is highlighted in red, indicating pressure being applied above the rated maximum working pressure.

10. When the pressing process is complete, turn the release valve anticlockwise in small increments to release ram pressure and allow removal of the workpiece and lower the protective screen.

TROUBLESHOOTING

Problem Probable Cause Remedy

Pump will not work. Dirt on valve seat/worn seals.

Bleed pump unit or have unit overhauled with new seals by your Clarke dealer.

Pump will not produce pressure.Pump feels hesitant under load.Pump will not lower completely.

Air-lock. Open the release valve and remove the oil filler plug. Pump the handle a couple of full strokes and close the release valve. Replace the filler plug.

Pump will not deliver pressure.

Reservoir could be over-filled or have low oil level.

Check oil level by removing the filler plug and topping up to the correct level.

Pump feels hesitant under load.

Pump cup seal could be worn out.

Have the cup seal replaced by your Clarke dealer.

Pump will not lower completely.

Air-lock. Release air by removing the filler plug.


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MAINTENANCE

ROUTINELYA visual inspection must be made before each use of the press, checking for leaking hydraulic fluid and damaged, loose, or missing parts.

Owners and/or users should be aware that repair of this equipment requires specialised knowledge and facilities. It is recommended that a thorough annual inspection of the press be made and that any defective parts be replaced with genuine Clarke parts.

If the press appears to be damaged in any way, is found to be badly worn, or operates abnormally SHOULD BE REMOVED FROM SERVICE until the necessary repairs are made.

If the press is not to be used for any length of time, store it with the ram piston withdrawn to protect the surface of the moving parts.

PERIODICALLYCheck the press to make sure all bolts are tight and inspect for cracked welds, bent, loose or missing parts.

Clean any foreign material from the ram carrier sliding plastic blocks. Keep the protective screen clean at all times.

Check the hydraulic connections for leaks. Replace or properly repair any damaged or leaking hydraulic components before using. In the event of leaking seals, oil can be topped up via the filler plug (P34-page 17) on the end of the pump. Oil should be level with the bottom of the hole. If necessary top up with CLARKE hydraulic oil, Part No. 3050830. This task is carried out with the ram fully retracted.

If any rust is apparent it must be removed completely and the paint restored.

DISPOSAL OF UNWANTED MATERIALSOne of the most damaging sources of environmental pollution is oil products. Never throw away used oil with domestic refuse or flush it down a sink or drain. Collect any oil in a leak proof container and take it to your local waste disposal site.

Should hydraulic components become completely unserviceable and require disposal, draw off the oil into an approved container and dispose of the product and the oil according to local regulations.


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TECHNICAL SPECIFICATIONS

Capacity 30 Tonne

Operating Pressure 20,000 Mpa

Ram Travel 152 mm

Ram Shaft Diameter 58 mm

Net Weight 167 kg

Dimensions D x W x H 700 x 800 (exc pump) x 1850 mm

Throat Width 530 mm

Bed Adjustment Distance 110 mm

No of bed positions 9

Throat Depth (Ram to pressing plate) Platform at highest;- 120 mmPlatform at lowest;- 557 mm

Ram travel per stroke 2.7 mm

No of strokes to full extension 64

Pressure Gauge type Accuracy class 2.5

Length of Handle 600 mm


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GENERAL ASSEMBLY PARTS DIAGRAM


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FRAME ASSEMBLY PARTS LIST

NOTE: When requesting spare parts, please quote the prefix JHCSA30FP followed by the number on the diagrams/parts lists here.

NO DESCRIPTION NO DESCRIPTION

1 Screw 29 Elbow Fitting

2 Spring 30 Screw

3 Ball 31 Lock Washer

4 Heel Block 32 Washer

5 Screw 33 Lock Washer

6 Bed Frame 34 Union Connector

7 Circlip 35 Nylon Ring

8 Pin 36 Union Seat

9 Screw 37 O-Ring

10 Support 38 Gauge Fitting

11 Screw 39 Pressure Gauge

12 Frame Foot 40 Connector

13 Washer 41 Hydraulic Hose

14 Lock Washer 42 Nut

15 Nut 43 Support

16 Screw 44 Bush

17 Ram Securing Collar 45 Spacer Tube

18 Ram Mounting Plate 46 Nut

19 Seating Ring 47 Nut

20 Ram Assembly 48 Foot Pedal

21 Screw 49 Bolt

22 Slide Block 50 Bolt

23 R-Clip 51 Bolt

24 Axle 52 Pump Protective Cover

25 Spring 53 Screw

26 Adjusting Bolt 54 Washer

27 Hydraulic Hose 55 Frame Assembly

28 O-Ring 56 Connecting Bar


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RAM PARTS DIAGRAM


R1 Ram R9 O-Ring

R2 Spring R10 PTFE Washer

R3 Screw R11 Piston Rod

R4 Nut R12 Washer

R5 Screw R13 Screw

R6 O-ring R14 End Ring

R7 PTFE Washer R15 Serrated Saddle

R8 Piston End


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PUMP PARTS DIAGRAM


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PUMP PARTS LIST


P1 Handle Socket P19 O-Ring

P2 R-clip P20 Screw

P3 Clevis Pin P21 Dust Cap

P4 Connecting Rod P22 Bolt

P5 Piston P23 Nut

P6 Piston P24 U-type limiter

P7 Nylon Ring P25 Washer

P8 PTFE Washer P26 Screw

P9 Retaining Ring P27 Long Release Valve

P10 Sealing Ring P28 O-Ring

P11 Piston Seat P29 Ball

P12 O-Ring P30 Release Seat

P13 Washer P31 Washer

P14 Ball P32 Pump

P15 Ball P33 Short Release Valve

P16 Ball Seat P34 Oil Filter

P17 Spring P35 Washer

P18 Screw P36 Screw


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DECLARATION OF CONFORMITY


Documents

30 TONNE HYDRAULIC PRESS - … · Thank you for purchasing this CLARKE 30 Tonne Hydraulic Press. ... Wear Safety Shoes Wear safety glasses ... F 1 x Pump Handle O 2 x Foot Pedal Connecting